FIELD OF THE INVENTION
The present invention relates to tool holder assemblies for use with industrial machines or equipment, and seating/securing components and activation systems for such assemblies.
BACKGROUND
Sheet metal and other workpieces can be fabricated into a wide range of useful products. The fabrication (i.e., manufacturing) processes commonly employed involve bending, folding, and/or forming holes in the sheet metal and other workpieces. The equipment used for such processes are of many types, including turret presses and other industrial presses (such as single-station presses), Trumpf style machines and other rail type systems, press brakes, sheet feed systems, coil feed systems, and other types of fabrication equipment adapted for punching or pressing sheet materials.
Concerning press brakes, they are commonly used for deforming metal workpieces, and equipped with a lower beam (or table) and an upper beam (or ram). One of the beams (typically the upper beam) is configured to be vertically movable toward the other beam. Forming tools are mounted to the beams so that when one beam is brought toward the other, a workpiece positioned therebetween can be formed, e.g., bent into an appropriate shape. Typically, the upper beam is configured to hold a male forming tool (a punch) having a bottom workpiece-deforming surface (such as a V-shaped surface), and the bottom beam is configured to hold an appropriately-shaped female tool (a die) having an upper surface vertically aligned with the workpiece-deforming surface of the male tool.
As is known, forming tools are commonly mounted to press brake beams using one or more tool holders provided on the beams. Particularly, upper portions of the tools, commonly referred to as tangs or shanks, are inserted between opposing walls of the holder, and these walls are configured to form a channel within which the tool tang can be secured. Quite often, the channel is defined via a stationary portion of the tool holder and an opposing movable portion of the holder.
In the pursuit of designing tool holders for industrial machines, e.g., for press brakes, many factors need to be considered. One factor relates to variability, particularly with respect to the various tooling styles that could be used, with such styles potentially having different tang profiles. For example, the surface or extent of the tang that extends upward from the tool safety slot can be straight (substantially vertical), beveled (having an angle from vertical), or curved. Some tool holders, e.g., designed for press brake applications, have been configured to require use of adaptors. While a viable solution for accommodating different tang styles, adaptors often necessitate proper positioning and/or maintenance for precisely regulating force, or else damage could result to the tangs and/or the tool holders from contact with the adaptors. Such regulation has conventionally been provided via hydraulic, pneumatic, electric, or other like means, whereby the applied forces can be precisely regulated. However, incorporation of regulating elements adds complexity and overall cost to the designs.
Another factor to consider in designing tool holders relates to tolerances. For example, there can be slight degrees of variance with each tool and tool holder design, such as with general dimensions of the tool (e.g., its tang) or actions of the tool holder (e.g., closing action(s) of one or more movable portions of the holder). When separately considered, these variances can be somewhat negligible; however, when encountered collectively, such as in the circumstance of loading forming tools in tool holders, such variances can result in a corresponding degree of play for the tooling. To account for such variances, some tool holders have been equipped with shape memory materials or structures such as springs to compensate for the tolerances with the designs in these areas. However, even with these elements, issues of looseness or play between tool and holder can arise over time, often due to wear. Moreover, such shape memory materials or structures may require periodic maintenance or replacement.
Further factors to consider in designing tool holders relate to fabrication and use of the tool holder. With respect to fabrication, if the tool holder is warranted both for new and retrofit designs, particularly for press brake applications, then the holder designs will need to be capable of being constructed/conformed to different lengths, as required, while also having some form of easily adaptable mounting system relative to its installation. Regarding use of the holder, questions may center around how the holder will be activated and how the activation will be divided/controlled across the tool holder. As already described, the activation force needs to sufficiently provide for securing the tooling, yet not be excessive whereby damage to the holder and/or tooling is a concern. In addition, the activation force may need to be regulated based on length of the tool holder to be used/activated and the tooling type to be secured. Incorporating such regulating elements to tool holder designs is possible, yet adds further complexity and overall cost to the designs.
Thus, there remains room for a tool holder assembly that can effectively and efficiently account for the above-described issues as well as others, and in doing so, provide a superior holder design.
SUMMARY OF THE INVENTION
Embodiments of the invention involve a tool holder assembly, as well as activation system used therewith. In some cases, the tool holder assembly is configured to shift as needed to engage tooling when the assembly is activated. For instance, the assembly has an activation system that is in fluid communication with one or more fingers via an intermediary. In some cases, the intermediary can include a fluid. In such cases, the fluid comprises liquid, gas, or both. In further cases, the intermediary can include a bladder that is transformable in shape, with the bladder filled with fluid. In other cases, the intermediary can involve a flexible diaphragm in which one or more of liquid (e.g., water or oil) and gas (e.g., air) are selectively driven into/out of the diaphragm. The intermediary is configured to correspondingly shift in position following the activation system being triggered, in which case the one or more fingers are correspondingly shifted into a tool channel of the tool assembly to engage tooling inserted therein. The tooling to be engaged is one or more tools, whereby the tang of each such tool can be engaged by one or more of the fingers. For some embodiments, the activation system is electrically triggered, upon which the one or more fingers are driven into a tool channel of the tool holder. With use of a solid or liquid for the intermediary, the fingers can be hydraulically driven. With use of a gas for the intermediary, the fingers can be pneumatically driven. In either case, a plurality of the tool holder assemblies can be adaptively joined to form a tool holder for one of or both the upper beam and lower beam of a press brake. In such cases, the extent of the tool holder can be correspondingly prescribed, based on the machine size.
Following set-up, select quantities of the tool holder assemblies provided across the beam can be used as needed, based on the intended machining job and the tooling required therefor.
In one embodiment, a tool holder assembly is provided, and includes a stationary portion that partially defines a tool channel, one or more movable portions situated opposite the stationary portion, and an electrical activation system and a driving system. The electrical activation system is in communication with the one or more movable portions, such that at least one of the one or more movable portions moves into the tool channel to secure tooling therein in response to the electrical activation system triggering the driving system.
In another embodiment, a tool holder assembly is provided, and includes a stationary portion that partially defines a tool channel, one or more movable portions situated opposite the stationary portion, and a driving system including a driven element that is in communication with the one or more movable portions via an intermediary, such that a movement of the driven element causes a movement of the intermediary which thereby causes at least one of the one or more movable portions to move into the tool channel to secure tooling therein.
In a further embodiment, a tool holder assembly is provided, and includes a plurality of modules operably linked together. Each module includes a stationary portion that partially defines a tool channel, one or more movable portions situated opposite the stationary portion, and a housing which contains an activation system and a driven element operably coupled thereto. The driven element is in communication with the one or more movable portions via an intermediary, wherein a movement of the one or more movable portions into the tool channel to secure tooling therein results from movement of the intermediary from a corresponding movement of a driven element, the driven element triggerable via the activation system.
In another embodiment, a tool holder assembly is provided, and includes a stationary portion that partially defines a tool channel, one or more movable portions situated opposite the stationary portion, and an activation system and a driving system. The driving system is hydraulic or pneumatic. The activation system is operably coupled to the driving system. The driving system is in communication with the one or more movable portions, such that at least one of the one or more movable portions moves into the tool channel to secure tooling therein in response to the activation system triggering the driving system.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings are illustrative of particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not necessarily to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
FIGS. 1A(i) and 1A(ii) are rear perspective translucent views of a tool holder assembly shown in unclamped and clamped configurations, respectively, in accordance with certain embodiments of the invention;
FIGS. 1A(ia) and 1A(iia) are side translucent views of the tool holder assembly of FIGS. 1A(i) and 1A(ii), respectively;
FIGS. 1B(i) and 1B(ii) are rear perspective translucent views of an alternate design of the tool holder assembly of FIG. 1A(i), shown in unclamped and clamped configurations, respectively, in accordance with certain embodiments of the invention;
FIG. 2 is a rear perspective translucent view of a further tool holder assembly in clamped configuration in accordance with certain embodiments of the invention;
FIG. 3A is a rear perspective translucent view of another tool holder assembly in accordance with certain embodiments of the invention;
FIG. 3B is a rear perspective translucent view of alternate tool holder assembly to the assembly of FIG. 3A in accordance with certain embodiments of the invention;
FIGS. 3C(i) and 3C(ii) are rear perspective and cross-sectional translucent views of another alternate tool holder assembly to the assembly of FIG. 3A in accordance with certain embodiments of the invention;
FIGS. 3D(i) and 3D(ii) are rear perspective and cross-sectional translucent views of further alternate tool holder assembly to the assembly of FIG. 3A in accordance with certain embodiments of the invention;
FIGS. 4A(i) and 4A(ii) are rear perspective bottom views of an alternate design of the tool holder assembly of FIG. 1A(i) in accordance with certain embodiments of the invention;
FIG. 4B is a front perspective view of the tool holder assembly of FIG. 1A(i);
FIGS. 4C(i) and 4C(ii) are front perspective bottom views of the tool holder assembly of FIG. 4A(i);
FIGS. 4D(i) and 4D(ii) are front and rear perspective views of a press brake machine, depicting an electrical system and lighting and clamping arrangements embodied relative to the tool holder assemblies of FIGS. 4A(i), 4B, and 4C(i) in accordance with certain embodiments of the invention;
FIG. 4E is an exemplary electrical diagram of the electrical system depicted in FIGS. 4D(i) and 4D(ii);
FIGS. 5A and 5B are front perspective translucent views of a tool holder assembly shown in clamped and unclamped configurations, respectively, in accordance with certain embodiments of the invention.
FIG. 6 is a front perspective view of an exemplary beam adaptor in accordance with certain embodiments of the invention;
FIGS. 7A and 7B are front perspective views of exemplary mounting configurations for groupings of the tool holder assembly of FIG. 4C as mounted on the beam adaptor of FIG. 6 in accordance with certain embodiments of the invention;
FIG. 8 is a front perspective view of a further mounting configuration for the tool holder assembly of FIG. 4C relative to an upper beam of a press brake in accordance with certain embodiments of the invention;
FIGS. 9A-9C are front perspective views of exemplary configurations of upper beams with which the tool holder assembly of FIG. 4C can be made to interface in accordance with certain embodiments of the invention;
FIG. 10 is a front perspective view of a mounting configuration for a holder assembly relative to a lower beam of a press brake in accordance with certain embodiments of the invention; and
FIGS. 11A-11C are front perspective views of exemplary configurations of lower beams with which a holder assembly can be made to interface in accordance with certain embodiments of the invention.
DETAILED DESCRIPTION
The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides some practical illustrations for implementing exemplary embodiments of the present invention. Examples of constructions, materials, dimensions, and manufacturing processes are provided for selected elements, and other elements employ that which is known to those of ordinary skill in the field of the invention. Those skilled in the art will recognize that many of the noted examples have a variety of suitable alternatives.
FIGS. 1A(i) and 1A(ii) are rear perspective translucent views of a tool holder assembly 10 shown in unclamped and clamped configurations, respectively, in accordance with certain embodiments of the invention. It should be appreciated that the holder assembly 10 can be coupled to either an upper beam or a lower beam of a press brake (e.g., see FIG. 4D(i)). Additionally, while the tool holder assemblies described herein are useful with a wide variety of common tool styles, such as American, European, Bystronic, and Trumpf/Wilson Tool, the assemblies would foreseeably function with other tool styles/tang types as well. Further, while the assembly 10 can be operatively coupled to a press brake beam via adaptor, a variety of designs and/or configurations (such as a Z1 or Z2 for Euro style beams, or Universal Bolt Pattern (UBP)) mounting direct to OEM upper beams could be used. As further alternative, the assembly 10 can be configured to have an integral coupling to join with a beam of the press brake, and thus not require a separate adaptor for such coupling. In further embodiments, the holder assembly 10 could be used with other industrial machines. For example, the tool holder assembly 10 can be used with machines configured to provide any of a variety of forming processes, such as bending, folding, and/or forming holes in sheet metal and other workpieces.
Continuing with FIGS. 1A(i) and 1A(ii), the illustrated tool holder assembly 10 includes two principal components for seating and securing tooling to the assembly 10, namely a stationary portion 11 and one or more movable portions. In certain embodiments, the stationary portion 11 is defined with a vertical side wall that (at least in part) defines (e.g., bounds) a tool channel 10aa. In using the term “vertical,” the skilled artisan is to understand that such side wall can be generally vertical, in that it be slightly sloped or curved, yet having generally vertical shape. In certain embodiments, the one or more movable portions comprise (or are) one or more fingers 30, which are shown extending toward the tool channel 10aa from a rear side of the assembly 10. Turning to FIGS. 1A (ia) and 1A (iia), each of the one or more fingers 30, in certain embodiments, is positioned in a corresponding pocket (e.g., a bore or other channel) 10bb of the tool holder 10. In the non-limiting example illustrated, the pocket(s) 10bb are in the rear side of the tool holder. The pocket(s) 10bb can be defined so as to be situated in side-by-side manner across an extent of the side of the holder assembly 10; however, the invention should not be so limited. For example, the pockets could be adjacently situated across the extent without being aligned side by side (e.g., could involve two or more lines of pockets, each line offset from the other) or without having equal spacing between consecutive pockets. When activated, the one or more fingers 30 move, e.g., toward and into (or further into) the tool channel 10aa of the holder assembly 10. As a result of this movement, the activated finger(s) 30 extend into the tool channel 10aa to correspondingly engage one or more tools T (e.g., tangs of the tools) loaded into the channel 10aa.
While the one or more fingers 30 (eight of which are exemplarily situated in the assembly 10) are not fully assessable in the views of FIGS. 1A(i)/(ia) and 1A(ii)/(iia), in certain embodiments, they all have substantially the same shape and length. Thus, distal ends 30a (or “tool-engagement ends”) of the fingers 30 are sized and shaped to correspondingly mate with a tool T received in the channel 10aa (e.g., by mating with a groove defined in a tang of the tool). When the electrical system 12 is activated, the fingers 30 are moved toward (e.g., into, or further into) the tool channel 10aa, with one or more of the fingers 30 contacting/engaging the tool (e.g., a tang thereof) loaded therein, as dictated by the desired machining operation. In certain embodiments, the distal ends 30a of the fingers 30 each have a leading end region with a ramp surface (e.g., see FIG. 1A (iia)) configured to engage tooling T when loaded in the tool channel 10aa. While application has been exemplified for use with tangs of tooling having grooves, the clamping assemblies (e.g., assembly 10) embodied herein can be used with tooling devoid of such grooves in their tangs.
In certain embodiments, the tool holder 10 has a length configured to extend along a length of an upper beam of a press brake, with the one or more fingers 30 being spaced apart along the length of the holder 10. Relative to securing (or “clamping”) the tool, the process involves opposing side surfaces of the tool (e.g., a tang thereof) being contacted by corresponding surfaces of the generally stationary portion 11 and one or more fingers 30. Preferably, such contacts collectively serve to fixedly clamp the tool between the finger(s) 30 and the stationary portion 11. In preferred embodiments, securing and seating of a tool within the tool channel 10aa occurs simultaneously. However (and as further detailed herein), seating a tool commonly involves a vertical lifting of the tool (e.g., via the tool tang) within the channel 10aa so that one or more tang upper surfaces are brought into contact (e.g. flush contact) with one or more corresponding surfaces of the stationary portion 11. Once clamped and seated, the tool is in an operative position, such that no further positioning steps are required prior to using the tool for its intended machining purpose. In the present embodiments, clamping and seating preferably occur simultaneously (e.g., by simply moving one or more fingers 30 in a common direction). In other cases, the tool(s) may simply be clamped, but not simultaneously seated during clamping.
In certain embodiments as shown, the stationary portion 11 includes one or more walls that bound the tool channel 10aa, which is configured for seating and securing tooling therein. For example, tooling can often be secured (or “clamped”) against a side wall of the stationary portion 11, while the tooling is also seated against one or more of an upwardly-facing lower wall and a downwardly-facing upper wall of the stationary portion 11. FIGS. 1A (ia) and 1A (iia) depict the tool holder assembly 10 in open/unclamped and closed/clamped configurations, respectively, as is further described herein relative to the triggering/actuation and driving clamping systems of the assembly 10.
As described above, many different types of activation/actuation systems (e.g., hydraulic, pneumatic, electrical, mechanical, or other like means) have been implemented over the years with tool holder designs. In many cases, such systems have resulted in exaggerated complexity and/or cost, particularly if activation needs to be regulated. It should be appreciated that any of these triggering/actuation systems could be adapted for use with clamping assemblies including the fingers 30 embodied herein. Relative to applicant's co-pending U.S. patent application Ser. Nos. 18/331,158 and 18/533,126, certain embodiments of the present clamp assemblies have electrical triggering/activation, and such assemblies are further provided with mechanical means that are correspondingly driven to provide requisite clamping force. Advantages of such system include design simplicity, corresponding case of maintenance, and flexibility relative to sizing assembly for shipping purposes and subsequent use.
In certain embodiments of the present invention, clamping of the tool holder assembly 10 is electrically triggered, but the clamping is a byproduct of hydraulics. Applicant has discovered that incorporating and marrying hydraulic (and/or pneumatic) driving/clamping with electrical triggering/activation enables certain advantages, such as managing tolerances (e.g., looseness) in the system, in various ways and over the life of the tool holder assembly.
Continuing with FIGS. 1A(i) and 1A(ii), in certain embodiments, triggering and driving components of the tool holder assembly 10 are self-contained within the assembly housing 10cc, with the driving elements, once triggered, configured to activate the finger(s) 30. The tool holder assembly 10 in its unclamped configuration, is depicted in FIGS. 1A(i)/(ia). Here, the fingers 30 are shown in retracted positions (within the pockets 10bb). The electrical activation source or system 12, in certain embodiments, includes a DC type motor 14a and gear box 14b with an output shaft 18. By their design, the motor 14a preferably is equipped to function at a certain voltage (e.g., 6v, 12v, or 24v) to provide certain RPM, with the gearbox 14b translating into a prescribed RPM for the output shaft 18. To that end, the speed and torque of the output shaft 18 are dependent on the internal configuration (or ratio) of the gearbox 14b. The motor 14a, in certain embodiments, has a worm gear that couples to the gear box 14b. With reference to FIG. 1A(ii), the gear box 14b is configured to generate rotation of the output shaft 18a, which can cause the shaft 18 to also move axially in an outward direction A, away from the gearbox 14b. This moves the illustrated piston 16 in the same direction A. As shown, the electrical triggering system 12 and the piston 16 are housed in a pocket (e.g. a bore) 20 defined in the housing 10cc. In certain embodiments, as shown, the piston 16 includes a gasket 26 (e.g., an O-ring, preferably formed of silicone) to prevent flow of fluid across the piston 16 (and out the housing 10cc via pocket 20).
With reference to FIG. 1A(i), fluid 28 (such as hydraulic fluid) is provided to fill a cavity 32 extending between a distal end of the piston 16 and proximal ends of the fingers 30. In certain embodiments, such cavity 32 includes one or more channels. For example, as shown, the cavity 32 includes an inner pocket 20′ and first and second channels 22, 24. Here, the second channel 24 is in fluid communication with proximal ends 30b of the fingers 30, and the first channel 22 is open to both the pocket 20′ and the second channel 24. In certain embodiments, as shown, each of the fingers 30 includes a gasket 26′ (e.g., an O-ring, preferably formed of silicone) to prevent flow of the fluid 28 across the finger 30 (and potentially out of the opening 10bb). In certain embodiments, as shown in FIG. 1A(ii), rotation of the shaft 18 (and corresponding movement of the piston 16) results in the fluid 28 imparting force on the fingers 30 so as to move them into the tool channel 10aa and thereby clamp tooling via the fingers 30. For example, upon actuating the motor 14a, the gearbox 14b is triggered to rotate the shaft 18, which correspondingly moves the piston 16 axially into a deeper position within inner pocket 20′. This causes the piston 16 to act on the fluid 28 within the pocket 20′, driving fluid 28 from the cavity 32 through the first channel 22 and into the second channel 24, thereby imparting requisite force on the proximal ends 30b of the fingers 30, so as to force them to move into the tool channel 10aa and thereby secure/seat tooling inserted therein via their leading ends 30a.
Exemplary parameters for the embodied configuration can include a 24v motor with gearbox having ratio of 600:1, such that 6000 RPM of the motor is translated by the gearbox to 10 RPM of the output shaft. Exemplary manufacturers for obtaining such motor/gearbox products are Fuzhou Bringsmart Intelligent Tech. Co., Ltd. (Fuzhou, China: www.bringsmart.com), Shenzhen Jinshunlaite Motor Co., Ltd. (Shenzen City, China: www.aslongdcmotor.com), and Need-for-Power Motor Co., Ltd. (Shenzhen, China: www.nfpmotor.com). It should be appreciated that other motor and optional gearbox configurations could be alternately used; the designs and examples noted herein are provided merely for exemplary purposes. Also, while reference is made to DC motors in the embodiments described herein, AC motors could be alternately used, or other motor types, such as pneumatic or hydraulic based.
Shifting back to FIGS. 1A(i) and 1A(ii) and relative to the fingers 30 shown therein, the fingers 30 are aligned across an extent of the assembly 10, such as by being spaced apart, diverging, or both. Here, the illustrated piston 16 is configured such that (a) it moves into a deeper position within the pocket 20′ (so as to decrease the volume available for fluid therein) in response to rotation of the output shaft 18 in first direction, and (b) it moves into a shallower position within of the pocket 20′ (so as to increase the volume available for fluid therein) in response to rotation of the output shaft 18 in a second direction. The first and second directions are selected from clockwise and counterclockwise.
In certain embodiments, the output shaft 18 can be a single body extending from the gear box 14b when rotated so as to correspondingly move the piston 16. Alternately, the output shaft may be designed to involve multiple elements. In certain embodiments, the electrical activation system 12 can include a gear box 14b configured with an output shaft operably coupled with a drive shaft stemming from the piston 16. For example, as shown, the output shaft of the gear box 14b could involve a male portion threadedly received within a female portion 18a of a drive shaft stemming from piston 16, so as to selectively couple the gear box 14b (and correspondingly, the system 12) to the piston 16. The male portion of such a multiple-element output shaft 18, in certain embodiments, has a shape, which mates with a correspondingly shaped aperture defined in the female portion 18a. In certain embodiments, the shape can be a multi-point star shape, such as a six-point star shape. Screw drives of such a configuration are sometimes referred to as a star drive. Certain commercial drives of this nature are sold under the tradename Torx. For now, the reader should appreciate that such male/female configuration enables installation and/or replacement of the electrical activation system to be easily and efficiently performed. To that end, it should be appreciated that the male and female portions of such an exemplary multiple-element output shaft 18 could be reversed relative to the gear box 14b and piston 16. Further detail regarding such installation/replacement is covered later. In certain embodiments, the female portion 18a has exterior threading to correspondingly mate with interior threading of a central bore of the piston 16. This is perhaps best appreciated with reference to FIG. 1A(ii).
In FIGS. 1A(i) and 1A(ii), activation of the electrical activation system 12 and triggered movement of the piston 16 (and corresponding hydraulic function) are exemplified. Upon activation of the electrical system 12 and a resulting rotation of the threaded output shaft 18, a corresponding advancement (e.g., movement deeper into pocket 20′) of the piston 16 occurs. Such advancement occurs due to the piston 16 being positioned in the pocket 20 of the tool holder 10, which retains the orientation of the piston 16, yet allows axial movement of the piston 16 as the shaft 18 rotates. To that end, when the electrical system 12 is actuated, the piston 16 moves in a first direction A within the pocket 20′, which results in at least some of the fluid 28 within cavity 32 be forced to move so as to force the fingers 30 into the tool channel 10aa. Upon advancing the fingers 30 into contact with the tooling (tang(s) thereof) when received in the tool cavity 10aa, the fingers 30 will secure the tooling (and in some cases, simultaneously seat the tooling) for subsequent use. While not shown, the skilled artisan would appreciate that biasing member(s) can optionally be provided for the fingers 30 to aid in their retraction from the tool cavity 10aa upon the electrical activation system 12 being disengaged. In certain embodiments, a bleed port 34 is defined to link with the pocket 20′ and aid in allowing air to escape the system. It should be appreciated that in using hydraulics as a method of power transmission, one attribute is its superior stiffness properties, which leads to such system providing an instant, accurate response. To minimize elasticity in such systems, a means of bleeding air is necessary, as a build-up of air will cause spongy response and reduced clamping power. In some configurations, as shown, the port 34 can have a threaded distal end, so as to be sealed with like-threaded screw.
In using the gearbox 14b, 14b′ (with worm gear drive) in combination with such motor 14a, 14a′, the systems 10, 10′ exhibit mechanical self-locking of the output shaft 18, 18′ when in a first (or “activated”) position via the gearing. As such, the piston 16, 16′ is maintained locked in the closed (or “clamped”) state, e.g., as shown in FIGS. 1A(ii) and 1B(ii). This first position represents a locked position for the shaft 18, 18′. Put another way, upon activation via the electrical system 12 or 12′ and the resulting securing of the tooling, the threading and gearing of the motor/gear box lock themselves in place, such that it is virtually impossible to move the tooling. Of course, the piston 16, 16′ can, when desired, be reversed from its locked position by further operating the system 12 (or system 12′). This mechanical self-locking enables the clamping force of the electrical system 12 (preferably between 50 lbs and 100 lbs) to be lower than is required for other actuation systems, yet just as effective. This locking property of the electrical systems 12, 12′ (from the motor/gearing) remains even if power is lost, which is not the case with other actuation systems. Using the electrical activation system 12 or 12′ as actuating source enables secure clamping for many applications using less clamping force (than other actuating systems) due to the nature of the mechanical locking properties of the activation system 12, 12′. However, in certain applications, more clamping force may be required (for larger size tooling). The present electrical activation systems 12, 12′ advantageously enable their design elements and parameters to be readily adaptable for such applications.
Continuing with the above description concerning the electrical activation systems 12 and 12′, it should be appreciated that the larger the clamping force, the slower the clamping speed (which is dictated by the speed of the output shaft 18, 18′). However, this is not a significant disadvantage because, as described above, the preferred electrical activation system 12, 12′ can function as needed with a relatively modest clamping force (optionally 50 lbs-100 lbs). Preferably, other variables are accounted for in providing for a preferred 50 lbs-100 lbs clamping force. Such variables include the distance the piston 16, 16′ needs to travel to engage/clamp the tool tang 102a and how many rotations of the output shaft 18, 18′ are required for such travel. For example, to achieve 70 lbs-100 lbs clamping force, the time needed to sufficiently rotate the shaft 18, 18′ in certain non-limiting embodiments is in the range of 5.4 seconds to 7.1 seconds. In certain embodiments, proceeding with a system of 70 lbs clamping force, with the output shaft 110c having M8x1.25 pitch, the system requires about 5.4 seconds for clamping. Increasing the pitch of the shaft 110c and/or decreasing the force to near, yet preferably not below, 50 lbs, enables the piston 16, 16′ to move farther in fewer rotations and/or in less time.
Alternately, in certain embodiments as described above, a multi-start threaded insert can be used as the female portion, relative to a multi-element shaft 18, 18′, to enable slow rotational speeds of the motor 14a to achieve faster clamping times. As noted above, using such a multi-start insert (or helix) as the female portion of the shaft 18, 18′ would effectively accelerate the linear motion corresponding to the rotational motion of the shaft 18, 18′ extending from the gearbox 14b, 14b′. One example, as noted above, could involve a 600:1 gear ratio for the motor 14a, 14′, which would generate about 10 rpm. Such 10 rpm motor, when used with a 10 mm pitched 5-start drive screw for the threaded insert serving as the female portion of the shaft 18, 18′, allows for significant clamping force (100 lbs-150 lbs) with an acceptable clamping speed ranging from 2 seconds to 2.5 seconds. By way of comparison, certain conventional hydraulic systems have tended to exhibit looseness unless substantially higher clamping forces (about 250 lbs) are maintained.
It should be appreciated that over time, the pressure of the fluid 28 may vary. For example, the fluid pressure may decrease over time with corresponding change of the tool holder assembly during its life. In certain embodiments, an optional pressure sensor can be provided to monitor the pressure and vary pressure accordingly. For example, with reference to FIG. 1A(i), upon sensing a drop in pressure below a pre-determined level, a sensor (e.g., situated in inner pocket 20′) would activate motor 14a for moving piston 16 deeper into the pocket 20′ to increase the pressure. A further example can be made with reference to the pump design of FIG. 2, in which the location for such pressure sensor 36 is in communication with, yet positioned outside, the pocket 20a′ (e.g., in a channel extending from the pocket 20a′). Additionally, in certain embodiments, a check valve could be positioned in communication with the pocket 20a′ to prevent flow in the opposite direction back through the pump. When using a check valve to prevent reverse flow, a solenoid valve can be further used to control the release of pressure to unclamp.
In certain embodiments, a relief valve can be optionally connected to fluid pump to replenish the fluid 28, and its warranted pressure, as needed. A pressure control valve could be used to prevent over-pressurization of the system by diverting excess fluid when the pressure reaches a set level. This helps protect the system from overpressure, which can lead to damage or failure of components, leaks, and potential safety hazards. In using a pump, a reservoir of fluid would also be needed, and this could be either inside the assembly housing 10cc or externally mounted. While the electrical triggering/activation system 12 has been embodied to use a gearbox 14b with a DC motor 14a, it should also be appreciated that the system can be configured to function without any gearbox. Using a gear box enables rotation to be altered, with corresponding effect on driving force generated.
Shifting to FIGS. 1B(i) and 1B(ii), the tool holder assembly 10′ shown is similar to the assembly 10 of FIGS. 1A(i) and 1A(ii), relating to components and function. However, instead of the electrical system 12′ and piston 16′ being generally horizontal in orientation relative to the extent of the tool holder assembly 10′, they are oriented generally vertically. To that end, the design is no longer self-contained relating to the electrical system 12′; however, such generally vertical orientation enables the extent of the assembly 12′ to be reduced in length. For example, in certain embodiments, while the assembly 10′ is exemplified with eight fingers 30 across its extent, the assembly 10′ can be reduced in length as desired, and different numbers of fingers 30 can be provided. In certain embodiments, the assembly 10′ has at least one finger 30, or perhaps more preferably, at least two to four fingers 30. With such versatility, the cost for shipping such assemblies of reduced sizes can be minimized, while the assemblies when received and later used, could be grouped together as needed (e.g., see FIG. 7A) to facilitate the warranted machining operations.
Relative to the above-noted concept of integral units, the assemblies 10, 10′ can be grouped together in a modular fashion to account for any beam length, enabling wide variability in terms of new and retrofit applications. With their integral activation/clamping, the tool holder assemblies 10, 10′ can be sized as desired. For example, differing tool holder assembly arrangements are depicted in FIGS. 7A and 7B. To that end, the arrangements share common modules, but have different lengths/different numbers of modules, which can enable more compact packaging and a savings relative to shipping. Upon reaching their destination, the tool holder assemblies 10, 10′ can be linked together (see FIG. 7A) to form the desired length/arrangement to be operably coupled to a press brake beam or to form a beam. Again, this flexibility relative to length of tool holder assembly 10, 10′ enables product packages to be shipped in much smaller sections, allowing for packaging to be smaller and palletized, rather than crated. Furthermore, in combination with triggering/activating the assembly 10, 10′ via electrical system 12, 12′, one is able to use hydraulic means for driving/clamping force, and without having to package and ship in standard 8′, 10′, 12′ or even longer lengths, which is typical for hydraulic tool clamping systems.
Shifting to FIGS. 2 and 3A-3D, each tool holder assembly 10b and 10c, 10c′, 10c″, 10c′″ has an electrical triggering/activation system 12 (motor 14a and gear box 14b) similar to that of the assembly 10 of FIGS. 1A(i) and 1A(ii), yet the driving/clamping functionality is provided via pump 40 (FIG. 2) or pump 50 (FIGS. 3A-3D). Starting with pump 40 design of FIG. 2, the electrical system 12, upon being triggered, causes rotation of lobes/vanes/gears internal to the pump 40, thereby pressurizing the fluid 28 in pocket 20a′ to exert warranted pressure across the fingers 30 to secure/seat tooling in the tool channel. In such design, it should be appreciated that rotation of the shaft 18 of the electrical system 12 corresponds with (e.g., drives) rotation of internal lobes/vanes/gears of the pump 40, which in one direction results in fluid (and pressure therefrom) being directed to bear forcibly against the fingers 30, whereas in the opposite direction results in the retraction of the fluid from the fingers 30 (or at least a decrease of pressure thereon). Likewise, the rotation of shaft 18c in the assembly designs of FIGS. 3A-3D corresponds with (e.g., drives) rotation of the pump gearing 52, which in one direction results in fluid (and pressure therefrom) being directed to bear forcibly against the fingers 30, whereas in the opposite direction results in the retraction of fluid (or at least a decrease of pressure) on the fingers 30.
Differing from the embodied design of FIG. 3A, the pump designs of FIGS. 3B-3D include a complementary bladder 54a, 54b (FIG. 3B, 3C(i) and(ii)) or a flexible diaphragm 56 (FIG. 3D(i) and(ii)). To that end, the rotation of the shaft 18 of the electrical system 12 in the bladder designs of FIGS. 3B and 3C(i) and(ii) corresponds with (e.g., drives) rotation of the pump gearing 52, which in one direction results in fluid (and pressure therefrom) being directed to the bladder 54a, 54b such that its exterior surface area expands so as to bear forcibly against the fingers 30, whereas in the opposite direction results in retraction of fluid from the bladder 54a, 54b (and thereby a release or at least reduction of pressure) on the fingers 30. In certain embodiments, as shown in FIGS. 3B and 3C(i) and(ii), the bladder 54a can comprise a singular bladder body, configured to contact (e.g., bear forcibly against) each of the fingers 30, or the bladder 54b can comprise separately regulated bladder bodies for respective fingers 30. Further, in certain embodiments, the bladder 54a can have a generally vertical orientation or the bladder 54b can have a generally horizontal orientation. Although, it should be appreciated that the bladder 54a/54b can alternatively be angled from horizontal or vertical. Relating to the flexible diaphragm 56 of FIG. 3D(i) and(ii), rotation of the shaft 18c of the electrical system 12 corresponds with (e.g., drives) rotation of the pump gearing 52, which in one direction results in fluid (and pressure therefrom) being directed to a diaphragm 56 such that its exterior surface area expands to bear forcibly against the fingers 30, whereas in the opposite direction results in the retraction of fluid from the diaphragm 56 (and release or reduction of pressure) on the fingers 30. In certain embodiments, the diaphragm can be a separately regulated diaphragm for each of the fingers.
Turning to FIGS. 4A-4C, in certain embodiments as shown, the tool holder assembly 10 can include a series of light arrangements. In certain embodiments, the lights comprise LED lights. One light arrangement, in certain embodiments with reference to FIGS. 4A(i) and 4A(ii), includes ambient down-facing lights 120, e.g., for illuminating the working space/surface of a press brake. These lights 120, in certain embodiments as shown, can be hidden from general view (e.g., positioned behind an optional shield 118), yet can be seen from a bottom view of the holder assembly 10a as shown in FIG. 4A(i). When provided, such lights can be on the rear side, front side, or both front and rear sides of the tool holder assembly. Alternately or in addition, in certain embodiments as shown in FIG. 4B, a light arrangement can involve front/side-facing lights 122, e.g., for signaling functions of the tool holder. In certain embodiments as shown, the lights 122 extend across and above an extent of the holder assembly 10a′ and can be exemplarily used for showing a state of each holder section. For example, the lights 122 could illuminate a red color at or above sections of the holder in the unclamped/open state and/or could illuminate a green color at or above sections of the holder in the clamped/closed state. In certain embodiments, both types of lights 120, 122 could be used in combination or alternately for signaling any of a variety of characteristics for the tool holder, depending on their design/orientation. For example, while either of the lights 120, 122 can be used for diagnostic purposes, as exemplified below, the downlights 120 would perhaps perform best in signaling desired bend lines, while signaling for next bends relative to staged bending, e.g., via blinking light of certain color, such as green color, is perhaps best done using the front/side lights 122. Further, the front/side lights 122 could be adapted to signal where/when to remove a tool, e.g., via blinking light of differing color, such as red color.
Turning to FIGS. 4C(i) and 4C(ii), another tool holder 10a″ is depicted, with a further downlighting configuration. Compared to the downlighting configuration of the assembly 10a of FIGS. 4A(i) and 4A(ii), the light sources (e.g. LEDs) 124 are situated more central to (i.e., closer to the tool channel of) the assembly 10a″. In certain embodiments, the light pathway (e.g., beam) 124′ is directed downward, e.g. generally toward a working surface. In embodiments of this nature, if the tool holder assembly 10a″ is also provided with down-facing lights 120, the further downlight from source 124 can be directed toward the working surface and used as desired.
It is to be appreciated that a given holder assembly can optionally include any one or more (such as any two or more, or all three) of(i) light sources 120, (iii) light sources 122, and (iii) light sources 124. Thus, a given tool holder assembly can optionally include any one, two, or all three such light source configurations/locations/arrangements. It should be noted that each of the light sources 120, 122, and 124 are shown as comprising a plurality of light sources. In certain embodiments, two or more (optionally all) of these sources 120, 122, and 124 can be used in unison for a single purpose, or they can be controlled independently for separate tasking (such as using one or more of the sources 120, 122, and 124 for projecting job specifics in combination with using one or more of the other sources for providing diagnostic information relating to the tool holder functionality, as later exemplified herein). Similarly, the plurality of lights of each such light source 120, 122, and 124 can optionally be used in unison for a single purpose, or controlled independently for separate tasking. In certain embodiments, the light intensity from each of the light sources 120, 122, and 124 can be varied, e.g., by flashing or changing color, such as to signal a safety concern.
Shifting to FIGS. 4D(i) and 4D(ii), a press brake machine 250 is shown, depicting an exemplary electrical system relative to clamping and lighting arrangements 120, 122, and 124 for the tool holder assemblies 10 on the tables 400, 400′ of the machine. In certain embodiments, the control for the machine 250 would transmit to a control box 270 to activate one or more down lighting configurations (e.g., of one or more of configurations of light sources 120 and 124) and front/side lighting 122, and to activate clamping and unclamping of the assemblies 10. The electrical drawing of FIG. 4E correspondingly shows an exemplary wiring schematic of one such system. It is to be appreciated, however, that these optional details are by no means required.
For example, upon receiving signals via the control box 270, an electronic control unit (ECU) 260 would be configured to run the motors for the activation systems of the clamp assemblies 10 and also control the downlighting (one or more of lighting configurations 120 and 124) and front/side lighting 122 (e.g., LED strip(s)) thereon. In certain embodiments, the ECU 260 has current sensing capabilities so as to monitor the draw and correspondingly deactivate the motors if a stall torque is reached. The ECU 260, in certain embodiments, can further control front/side lighting 122, e.g., making them blink during transition and/or turning one color (e.g., red) for unclamped status and another color (e.g., green) for clamped status. In certain embodiments, one or more of downlights 120 and 124 can be likewise controlled to perform such signaling/function.
In certain embodiments, in the event the ECU 260 senses a current issue, front/side lighting 122 can be made to provide a problem signal (e.g., by blinking or displaying a different color). In certain embodiments, the ECU 260 can also be configured to provide differing code signals e.g., fast and/or slow flashes, to signify differing problems. For example, if the ECU 260 sensed a condition of no current from a clamp assembly, the corresponding code signal could be five rapid pulses flashed with a 5 second delay, then repeated. This would signal that, with no current, the motors are not functioning/responding. As another example, in the event of sensing a high current draw early during a clamping cycle, there could be two rapid pulses flashed followed by two slower pulses with a 5 second delay, then repeated. This would signal that, with such high current draw, the clamp fingers are likely stuck, with stall torque being reached sooner in the clamping cycle than expected. It should be appreciated that other scenarios may exist that dictate further monitoring, using the current sensing feature of the ECU 260, whereupon signal diagnostic warnings could be correspondingly displayed via front/side lighting 122. In certain embodiments, one or more downlighting configurations 120 and/or 124 can be likewise controlled to perform like signaling/function. In certain embodiments, each clamp assembly unit 10 is monitored independently, and as such, could be triggered to display its own diagnostic warning, thereby enabling the user to quickly identify which unit has the issue and what the specific issue is.
Turning to the design of FIGS. 5A and 5B, the electrical means for triggering/activating the assembly 10d is replaced with a mechanical lever 60, which when rotated in one direction (FIG. 5A), corresponds with forward movement of operatively-coupled piston 16″, and when rotated in the opposing direction (FIG. 5B), corresponds with rearward movement of the piston 16″. To that end, and similar to the assembly 10 of FIGS. 1A(i) and 1A(ii), the forward movement of the piston 16″ corresponds with fluid 28 (and pressure therefrom) being exerted on the fingers 30.
In certain embodiments, and relative to the tool assemblies embodied herein (but only noted here relative to assembly 10 of FIGS. 1A(i) and 1A(ii)), the overall length of the assembly 10 and/or spacing between fingers 30 thereof can be established/standard parameters. For example, in certain embodiments, the length of the assembly 10 can range from 150 mm to 250 mm. In more preferable embodiments, the assembly 10 can range in length from 170 mm to 200 mm. Regarding the spacing between fingers, this would be somewhat dependent on the length of the assembly 10. In certain embodiments, the spacing can range in length from 0 mm to 50 mm. In more preferable embodiments, the spacing can range in length from 10 mm to 40 mm; in even more preferable embodiments, the spacing can range in length from 20 mm to 30 mm; and in preferred embodiments, the spacing can range in length between 20 mm and 25 mm.
Relative to the advantageous concept of modular units, the tool holder assemblies embodied herein (but illustrated relative to assembly 10 of FIGS. 1A(i) and 1A(ii)) can be grouped together to account for any beam length, enabling wide variability in terms of new and retrofit applications. As a result, a savings in packaging and shipping can be realized. For example, upon reaching their destination, the tool holder assemblies 10 can be linked together (to form the desired length/arrangement) to be operably coupled to a press brake beam. Once collectively grouped on a press brake beam (or table), any individual or combination of holder assemblies 10 (and their fingers 30) may be used for machining applications along the beam lengths.
This flexibility relative to length of tool holder assembly enables product packages to be shipped in much smaller sections, allowing for packaging to be smaller and palletized, rather than crated. These assemblies can be greatly reduced in size, compared to conventional hydraulic beams, which must be fully assembled and then shipped in the standard 8′, 10′, 12′ or even longer lengths.
Shifting to FIG. 6, a beam adaptor 310 is illustrated, which, in certain embodiments, is configured to function with the modular tool holder assemblies 10 of FIGS. 1A(i) and 1A(ii). To that end, the adaptor 310 is used to mount to a specific OEM mounting option (Euro style Z1 or Z2, UBP, etc.) and can be formed to have any applicable length. In use, the upper surface 312 of the adaptor 310 is attached to an upper (or lower) beam of a press brake, and one or more assemblies 10 can be attached to adaptor 310 via the mounting bar 314. As shown, the bar 314 is defined with a series of mounting holes 316 located at spaced-apart positions along its length. Shifting to FIG. 7A, each assembly 10 is configured with one or more (e.g., a pair of) mounting fasteners (e.g., threaded fasteners, such as bolts or screws) 302, which are located/spaced so as align with the hole spacing of the mounting bar 314. Accordingly, the tool holder assemblies 10 can be mounted to the adaptor 310 as warranted. To that end, FIGS. 7A and 7B illustrate tight and spaced-apart arrangements of such assemblies 10, respectively. Relative to the spaces 318 shown between the assemblies 10 in FIG. 7B, it should be appreciated that the spacing can be varied as needed to provide the warranted tool holder set-up.
From the mounting configurations illustrated via FIGS. 7A-7B, a few advantages should be realized. For example, in the event of a damaged section, that section alone can simply be replaced by removing its fastener(s) 302 and pulling the damaged section from the beam adapter 310, while unplugging the supply cable. Steps for doing so may take about 5-10 minutes, compared to days or weeks relative to a service call for a broken solid beam. Also, in the event of a damaged section, the remainder of the holder assemblies 10 continue to function, as compared to an entire beam being potentially unusable until a repair is made relative to one outage area along the beam.
As alluded to relative to FIGS. 1A(i) and 1A(ii) and FIGS. 1B(i) and 1B(ii), the use of male and female portions for an output shaft 18, 18′ of a gear box 14b, 14b′ of the electrical activation system 12, 12′ enables those portions to be easily pulled apart as needed for maintenance or repair to the electrical system 12, 12′. Furthermore, in some embodiments, the motors 14a, 14a′ can be replaced simply by removing screws on the assembly 10, 10′, removing a cover, unplugging the motor 14a, 14a′ and sliding the male portion out from its linkage to the female portion, thereby freeing the electrical system 12, 12′ for retrofitting/replacement. In some preferred embodiments, those steps would only take about 5-10 minutes, compared to days or weeks relative to a service call for a broken solid beam.
Thus, embodiments of a TOOL HOLDER ASSEMBLY, AND SEATING/SECURING COMPONENTS AND ACTIVATION SYSTEMS THEREFOR are disclosed. One skilled in the art will appreciate that the invention can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the invention is limited only by the claims that follow.
Patent Application
20250229315
